FIELD
[0001] This disclosure relates generally to a mold, a molding apparatus, and a method for
manufacturing articles or components of articles. More specifically, the disclosure
relates to a mold, a molding apparatus and a method of using an ultraviolet (UV) curable
material to form an article or a component of an article, including a molded footwear
or sporting equipment component.
BACKGROUND
[0002] The statements in this section merely provide background information related to the
present disclosure and may not constitute prior art.
[0003] Conventional molding processes generally involve heating a thermoplastic polymer
resin to a temperature that allows the polymer to flow under pressure, injecting or
extruding the polymer into a cavity formed within a mold or die, and allowing the
polymer to cool, thereby, forming a finished product that is in the shape or form
of the cavity. Materials which react to form thermoset polymers may be used in a molding
process without the need to cool the material to solidify it and form a product that
has the shape of the cavity. When these materials are used, the mold is maintained
at a temperature and pressure that causes the polymers to cure or cross-link via a
chemical reaction to form a thermoset material.
[0004] Polymeric materials that are capable of curing upon exposure to ultraviolet (UV)
radiation are normally not selected for the manufacture of articles or components
of articles that are relatively thick in at least one dimension and/or exhibit a complex
geometry. Since UV curable resins only cure in regions that are exposed to a threshold
level of UV radiation, a thick component or one having a complex geometry may suffer
from one or more regions remaining uncured. Thus, UV curable resins are normally used
only to form thin layers, such as those found in the application of coatings or adhesives.
[0005] The molds used in conventional molding processes are usually expensive to build and/or
replace. These molds are often made of steel in order to withstand the high temperature
and/or pressure requirements of the molding process. The cost of these molds may further
be increased when the surface of the metal that forms the cavity of the mold needs
to be polished or textured.
PRIOR ART
[0006] There now follows a description of prior art that provides background information.
[0007] EP1434211A1 discloses a surface treatment of a light transmission layer by spin coating. When
a light transmission layer is to be formed by spin coating, the transfer of an information
recording layer is carried out using a resin stamper having a convex portion in an
outer peripheral portion.
[0008] EP1378898A1 discloses a stamper that can be separated (released) from a layer of photo-curing
resin. A process for producing an optical multi-layer recording medium is also provided.
The process for producing an optical multi-layer recording medium includes the steps
of: laminating a later of non-cured photo-curing resin and a transparent stamper made
of amorphous polyolefin resin in this sequence on a substrate; curing the non-cured
photo-curing resin with light permeated through the transparent stamper, and removing
the stamper.
[0009] US2012/0021151A1 discloses shaped articles made with a partially crystalline, cycloolefin elastomer
of norborene and ethylene typically having at least one glass transition temperature
(Tg) in the range of -10°C to 15°C and a crystalline melting temperature in the range
of 60°C to 125 °C and a crystallinity by weight in the range from 5% to 40%. The shaped
articles may be in form of medical tubing; a contact lens mold or component thereof;
a container such as a bottle, a squeeze bottle or a squeeze tube; an eyedropper or
eyedropper component; an elastomeric closure, a pierceable elastomeric closure, or
the shaped article is selected from shrink film and/or shrink tubing.
[0010] US2016/0362552A1 discloses photocurable millable polyurethane gum compositions that contain a millable
polyurethane gum having ethylenic unsaturation, a photocatalyst, and a low molecular
weight cross-liner containing minimally two ethylenically unsaturated groups. The
compositions can be used to continuously extrude profiles which retain their shape.
[0011] WO2017/007533A1 discloses a shaped footwear device intended to be used as a supportive insole or
orthotic, and a system and methods for making the same. The footwear device includes
a top foam layer, a light-cured composite material layer, and bottom textile layer.
The footwear device is created by conforming a pre-cured insole assembly to the plantar
surface of a foot or foot mold, and then exposing the pre-cured insole assembly to
light to create a shaped foorwear device with a light cured composite material support
plate.
[0012] WO2016/089462A1 discloses a sole structure for an article of footwear, which includes a sole component
having a plurality of hollow polymeric elements in contact with one another, or with
binder between the hollow polymeric elements and fixed relative to one another. A
method of manufacturing a sole structure for an article of footwear is also disclosed,
and includes placing a plurality of hollow polymeric elements in contact with one
another or with a binder between the hollow polymeric elements, and fixing the plurality
of hollow polymeric elements relative to one another to form a sole component.
[0013] WO2012/170008A1 discloses a method of producing a shaped article from a UV-curable silicone rubber
composition by irradiating said UV curable composition with UV-light. The method comprises
the steps of (i) filling a UV-curable silicone rubber composition into a thermoformed
UV-transparent mould which is made from a thermoplastic UV-transparent polymer, and
(ii) curing said UV-curable silicone rubber composition within said thermoformed UV-transparent
mould by irradiation with UV-light; said shaped articles being in the form of an electrical
insulator for indoor and outdoor use; and electrical articles comprising an electrical
insulation made by the method according to the present invention.
[0014] WO2018/200362 discloses an article of apparel or sporting equipment, such as garments and footwear,
which incorporates a molded component formed of a UV radiation curable material. In
the case of an article of footwear, the UV radiation material may be formed into an
outsole. The method of manufacturing such articles includes placing an ultraviolet
radiation curable material in contact with a molding surface, conforming the UV radiation
curable material to a shape of the molding surface, forming a molded component, and
removing the molded component from the molding surface, such that the component maintains
the shape of the molding surface. The molded component may be exposed to ultraviolet
radiation in an amount and for a duration that is sufficient to partially cure or
fully cure the UV radiation curable material.
DRAWINGS
[0015] In order that the disclosure may be well understood, there will now be described
various forms thereof, given by way of example, reference being made to the accompanying
drawings, in which:
Figure 1A is perspective top-down view of a mold apparatus formed according to the
teachings of the present disclosure;
Figure 1B is a perspective view of the bottom portion of the mold shown in Figure
1A;
Figure 1C is a perspective view of the interior of the top portion of the mold shown
in Figure 1A;
Figure 2A is a flow chart of a method of forming a mold according to the teachings
of the present disclosure;
Figure 2B is a flow chart of a method of forming an article or a component of an article
using the mold of Figure 2A;
Figures 3(A-C) are perspective views of articles or components of articles formed
according to the method of Figure 2B;
Figures 4(A-B) are perspective views of another article or a component of an article
formed according to the method of Figure 2B;
Figure 5 is a flow chart of a method of forming an article of footwear according to
the teachings of the present disclosure;
Figure 6 is a perspective view of a mold apparatus formed according to the teachings
of the present disclosure that may be used to manufacture an article from a UV radiation
curable material; and
Figures 7(A-E) is a perspective view of another mold apparatus formed according to
the teachings of the present disclosure that may be used to manufacture a component
of an article from a UV radiation curable material.
[0016] The drawings described herein are for illustration purposes only and are not intended
to limit the scope of the present disclosure in any way.
DETAILED DESCRIPTION
[0017] The use of ultraviolet (UV) radiation curable materials in forming or at least partially
forming an article or a component of an article offers multiple benefits to a manufacturing
operation. More specifically, the use of such materials may increase productivity,
lower costs associated with the fabrication of a mold, lower energy costs, and induce
less part shrinkage due to low curing temperatures and faster cure times. However,
in order to process such materials, the manufacturing operation needs to include equipment
and processes that allow the UV radiation curable materials to be exposed to ultraviolet
(UV) radiation for a duration of time that is necessary to at least partially cure
the material. The present disclosure generally relates to a mold, a molding apparatus,
and a method of using UV curable materials to form an article or a component of an
article, including a molded footwear or sporting equipment component.
[0018] According to one aspect of the present disclosure, a method according to claim 1
is provided.
[0019] A mold used to form a molded article may be made by a method that includes forming
a mold wall comprising a cyclic olefin copolymer and having a molding surface for
contact with an article-forming material for forming the molded article. When necessary
or desirable the step of forming the mold wall may comprise introducing a molten cyclic
olefin copolymer to a master mold and solidifying the molten cyclic olefin copolymer
in the master mold to form the mold wall.
[0020] In the method for forming a molded article, an article-forming material is introduced
in to a mold that includes a mold wall comprising a cyclic olefin copolymer. The article-forming
material makes contact with a molding surface of the mold wall in order to form the
molded article.
[0021] According to another aspect of the present disclosure, a method of manufacturing
an article of footwear according to claim 13 is provided.
[0022] An apparatus for forming a molded article includes a mold having a mold wall that
comprises a cyclic olefin copolymer and that is substantially transparent to UV light.
The mold wall has a molding surface for contacting an article-forming material. An
UV light source is advantageously disposed adjacent to the mold wall on a side opposite
the molding surface and configured to generate UV light for transmission through the
mold wall to the molding surface for exposing the article-forming material to the
UV light.
[0023] Thus, the present disclosure generally provides a method for manufacturing articles
or components of articles. The article or component of the article at least partially
comprises an UV radiation curable material. Thus, the method of molding the article
or component of the article may include exposure of the UV radiation curable material
to UV radiation for a period of time that allows at least partial cure thereof. Further
areas of applicability will become apparent from the description provided herein.
[0024] The following description and specific examples are merely exemplary in nature and
is in no way intended to limit the present disclosure or its application or uses.
For example, the molded component comprising an UV radiation curable material made
and used according to the teachings contained herein is described throughout the present
disclosure in conjunction with footwear in order to more fully illustrate the composition
and the use thereof. The incorporation and use of such a molded UV radiation curable
component in other applications, including apparel such as garments, sporting equipment,
or the like, as well as components thereof, are contemplated to be within the scope
of the present disclosure. It should be understood that throughout the description,
corresponding reference numerals indicate like or corresponding parts and features.
[0025] Referring to Figures 1A-1C, the mold 1 generally comprises a cavity 5 formed in a
bulk material 10. At least a portion of the surface of cavity 5 within the mold 1
is formed of a mold wall 15 comprised of one or more cyclic olefin copolymers as further
described herein. The surface of this mold wall 15 (i.e., a molding surface) is in
contact, either directly or indirectly, with the UV radiation curable material or
resin that is placed within the mold 1 to form an article or a molded component of
the article. Alternatively, the molding surface or the surface of the mold wall 15
is in direct contact with the UV radiation curable material used to form the article
or the molded component of the article. The molding surface may exhibit a surface
energy that is in the range of about 15 dynes/cm to about 35 dynes/cm at 20°C. Alternatively,
the surface energy of the molding surface is between about 20 dynes/cm to about 30
dynes/cm. The mold may be used to form a molded footwear component, a molded apparel
component, or a molded sporting equipment component. Alternatively, the mold is used
to form a molded footwear component.
[0026] For the purpose of this disclosure the terms "about" and "substantially" are used
herein with respect to measurable values and ranges due to expected variations known
to those skilled in the art (e.g., limitations and variability in measurements).
[0027] For the purpose of this disclosure any range in parameters that is stated herein
as being "between [a 1
st number] and [a 2
nd number]" or "between [a 1
st number] to [a 2
nd number]" is intended to be inclusive of the recited numbers. In other words the ranges
are meant to be interpreted similarly as to a range that is specified as being "from
[a 1
st number] to [a 2
nd number]".
[0028] The cyclic olefin copolymers comprise one or more amorphous, transparent copolymers
based on cyclic olefins and linear olefins. The cyclic olefin copolymers may include
copolymers that have the general formula shown in Equation 1, where x and y represent
integers that defines the ratio of linear to cyclic segments (e.g., ratio of x to
y) in the cyclic olefin copolymer. Alternatively, the cyclic olefin copolymer may
comprise a copolymer of polyethylene and norbornene.
[0029] The cyclic olefin copolymers provide the benefits of being at least partially transparent
to UV radiation, low density, low birefringence, low water absorption, high heat deflection
temperature, and good processability (e.g., flowability), as well as high strength,
hardness, and rigidity. Alternatively, the cyclic olefin copolymer used to form the
mold wall 15 is substantially transparent to UV light or radiation and allows the
UV radiation to be transmitted through the mold wall 15 to the molding surface and
to the UV radiation curable material used to form the article or the molded component
of the article. Several specific examples of cyclic olefin copolymers include, without
limitation, materials that are commercially available under the tradenames TOPAS®,
including TOPAS® 6017 and TOPAS® 6015, (Topas Advanced Polymers, Florence, KY, USA)
and APEL™ (Mitsui Chemicals Inc., Tokyo, Japan).
[0030] The cyclic olefin copolymers exhibit transparency on the order of about 80% to 100%,
alternatively, about 90% for light that is in the near ultraviolet region (i.e., -300
nm to -400 nm wavelength) and visible region (i.e., -400 nm to -700 nm wavelength).
The cyclic olefin copolymers may further exhibit transparency of light within a wavelength
ranging from about 250 nm to less than 300 nm that is on the order of about 10% to
about 85%. In some examples, the cyclic olefin copolymers exhibit greater than about
20% light transmittance.
[0031] In order to more easily process the UV radiation curable material, as well as provide
a buffer between processing and deflection, a mold comprising a cyclic olefin copolymer
that exhibits a high deflection temperature (HDT) may be desirable. Typically, a cyclic
olefin copolymer with a higher cyclic olefin component (i.e., segment y) will exhibit
a higher heat resistance. In this respect, the cyclic olefin copolymer may exhibit
a heat deflection temperature (HDT) at 0.46 MPa of at least 140°C as characterized
by HDT testing in accordance with the ISO 75-1 Test Standard. Alternatively, the HDT
of the cyclic olefin copolymers ranges from about 165°C to about 200°C. Several specific
examples of commercially available cyclic olefin copolymers that have an HDT in this
range include, without limitation, Topas® 6015 and 6017 (Topas Advanced Polymers Inc.)
with an HDT of 150°C and 170°C, respectively.
[0032] The cyclic olefin copolymer may be pre-compounded as sheets or be in the form of
a pelletized material, flakes, strips, or any other form as desired or necessary to
meet application requirements. The cyclic olefin copolymer may be milled to provide
a thinner thickness and/or to reduce the presence of air voids. When desirable, the
cyclic olefin copolymer may be dried to remove any residual moisture prior to be formed
into a mold. Although optional, pre-drying the cyclic olefin polymer may reduce the
amount of moisture splay present in the mold wall formed therefrom, resulting in an
increased level of optical transparency. Any known method of pre-drying the cyclic
olefin copolymer may be utilized. These methods may include but not be limited to
drying the cyclic olefin copolymer in a dehumidifying oven at 80°C or higher for a
predetermined amount of time, such as for example, a period greater than about 1 hour;
alternatively, greater than about 2.5 hours; alternatively, greater than about 4 hours.
[0033] Referring once again to Figures 1A-1C, the bulk material 10 of the mold 1 may be
comprised of a metal or metal alloy, a thermally stable polymer material, a ceramic
material, or a mixture thereof. The mold 1 may be used, without limitation, in a compression
molding operation or an injection molding process. Optionally, the mold 1 may comprise
mechanical features and connections that allow one or more molding surfaces 15 located
in the cavity 5 to be heated and/or cooled.
[0034] The bulk material 10 portions of the mold 1 may be manufactured from planar sheet
materials that have a constant thickness. When desirable this sheet material may include
a plurality of UV radiation deflecting particles within the bulk material 10 or positioned
on the surface of the bulk material 10, such as incorporated within a coating applied
thereto. For the purpose of this disclosure, a UV radiation deflecting particle means
any particle capable of diverting the direction of the transmitted UV radiation by
scattering and/or reflection thereof.
[0035] The bulk material 10 may be transformed into the desired shape of the article or
component of the article by any known process, including but not limited to, machining,
thermoforming and/or assembling, such that the interior contour of the cavity 5 represents
the negative or positive form of the article or component of the article that is to
be shaped within the mold 1.
[0036] The wall thickness of the bulk material, as well as thickness of the mold wall that
comprises the UV transparent material (i.e., the cyclic olefin copolymer) can vary
from about 0.5 millimeters (mm) to about 75 mm, allowing for the manufacture of flexible
or rigid molds. Alternatively, the wall thickness of the bulk material and/or UV transparent
mold wall is within the range of about 1.0 mm to about 50 mm; alternatively, within
the range of about 1.5 mm to about 30 mm; alternatively, within the range of about
2.0 mm to about I5 mm; alternatively within the range of about 2.0 mm to about 10
mm.
[0037] The inner volume of the cavity may allow for the formation of a molded component
having a thickness that is greater than about 0.05 millimeters (mm); alternatively,
with the range of about 0.05 mm to about 1.0 cm; alternatively, within the range of
about 1.0 mm to about 5.0 mm. The thickness of the molded article or molded component
of the article may be variable over the length and/or width of the article or the
molded component. The thickness of the bulk material 10 and the UV transparent mold
wall 15 that are within the indicated range provide a mold 1 that is durable for use
through multiple molding cycles.
[0038] In particular examples, the UV transparent mold wall, the molding surface, or both
the UV transparent mold wall and the molding surface exhibits transparency on the
order of about 80% to 100%, alternatively, about 90% for light that is in the near
ultraviolet region (i.e., -300 nm to -400 nm wavelength) and visible region (i.e.,
-400 nm to -700 nm wavelength). The UV transparent mold wall, the molding surface,
or both the UV transparent mold wall and the molding surface may further exhibit transparency
of light having a wavelength ranging from about 250 nm to less than 300 nm that is
on the order of about 10% to about 85%. In some examples, the mold wall, the molding
surface, or both the UV transparent mold wall and the molding surface exhibits greater
than about 20% light transmittance.
[0039] The mold 1 may comprise more than one part or die portion 1a (Fig. 1B), 1b (Fig.
1C) that fit together to form the cavity 5 bordered by the molding surface(s) 15.
The different parts 1a, 1b of the mold may be designed to be held together using a
variety of different fasteners, including without limitation, the mating combination
of pins 11 and sockets 13. In other words, the mold wall 15 may form at least part
of a first die portion 1a, and the mold 1 further comprises a second die portion 1b,
wherein the first and second die portions 1a, 1b are configured to move relative to
each other between an opened position and a closed position, and wherein the first
and second die portions 1a, 1b in the closed position defines a cavity 5 for molding
the UV radiation curable material that forms the article or the molded component of
the article. When the mold 1 is used in a compression molding process, the first and
second die portions 1a, 1b may be configured for compression molding the UV radiation
curable material to form the molded article or the molded component of the article.
[0040] Referring again to Figure 1A, the mold 1 may form part of a molding apparatus 20,
which also comprises an UV light source 25. The UV light source 25 and the mold 1
may be separable from each other or inherently combined to form the molding apparatus
20. In other words, the apparatus 20 may comprise a mold 1 made of only one or of
a plurality of mold or die portions 1a, 1b that can be fitted together to form the
mold 1 and separated from each other to release a manufactured product from the mold
1. Alternatively, the apparatus 20 may further comprise a conveyor system or similar
mechanism to move the mold 1 or the UV light source 25 into a position in which the
UV radiation arising from the light source 25 is aligned with the UV transparent portion
of the mold wall 15. One specific example, among many examples, of an apparatus 20
that comprises a conveyor system capable of moving a separable mold past an UV light
source is the LC6B/LC6B-2 UV curing unit available from Heraeus Noblelight America
LLC (Gaithersburg, MD).
[0041] The UV light source 25 generates UV radiation of which at least a portion thereof
is transmitted through the molding surface 15 to the article-forming or UV radiation
curable material placed within the cavity 5 and in contact with molding surface 15.
In other words, the apparatus 20 comprises a mold 1 having a mold wall 15 that comprises
a cyclic olefin copolymer and that is substantially transparent to ultraviolet (UV)
light, wherein the mold wall 15 has a molding surface for contacting an article-forming
material; and an UV light source 25 disposed adjacent to the mold wall 15 on a side
opposite the molding surface and configured to generate UV radiation for transmission
through the mold wall 15 to the molding surface for exposing the article-forming material
to the UV light.
[0042] The UV light source may include any type of UV light that transmits UV radiation
in a wavelength to which the cyclic olefin copolymer used in the mold wall is at least
partially transparent (e.g., can be at least partially transmitted there through).
Several examples of UV light sources, include but are not limited to, xenon lamps,
mercury lamps, black-light lamps, excimer lasers and UV-LED lamps. Alternatively,
the UV light source is an UV-LED lamp; a low, medium, or high pressure mercury vapor
lamp; a xenon lamp; a quartz halogen lamp; or a laser operating in the short wavelength
portion of the spectra. Several more specific examples of UV light sources include,
but are not limited to, short-wave UV lamps, gas-discharge lamps, ultraviolet LEDs,
UV lasers, tunable vacuum ultraviolet (VUV) obtained from sum and difference frequency
mixing, or plasma and synchrotron sources of extreme UV radiation. When desirable
more than one light source may be used with each light source being individually selected.
When desirable or determined necessary, the irradiation intensity of the UV light
at the previously defined wavelength to which the UV radiation curable material is
exposed may be within the range of about 0.5 W/cm
2 to about 5 W/cm
2; alternatively, about 1.0 W/cm
2 to about 4.0 W/cm
2; alternatively, within the range of 1.5 W/cm
2 to 4.0 W/cm
2.
[0043] Referring now to Figure 2A, a method 100 of making a mold for use in forming a molded
article or component of an article from a UV radiation curable material is provided.
This method 100 comprises forming 110 a mold wall that comprises a cyclic olefin copolymer
and has a molding surface for making contact with the article-forming material (i.e.,
the UV radiation curable material). The mold wall may be formed by introducing 115
molten cyclic olefin copolymer to a master mold and allowing the molten copolymer
to solidify 120 in the master mold, thereby, forming the mold wall. The master mold
includes a cavity encompassed by molding surfaces that is the negative or positive
image of the shape desired for the mold that will be used to form a molded article
or component from the article-forming (i.e., UV radiation curable) material.
[0044] The introduction 115 of the molten cyclic olefin copolymer into the master mold may
be, without limitation, part of an injection molding process 125 or an extrusion process.
The cyclic olefin copolymer is heated to a temperature that ranges from about 260°C
to about 320°C; alternatively, ranging from about 260°C to about 310°C; alternatively,
from about 270°C to about 320°C, prior to being introduced 115 into the master mold.
The molten cyclic olefin copolymer is solidified 120 in the master mold, which is
maintained at a lower temperature. The temperature of the master mold may be about
160°C or less; alternatively, in the range from about 120°C to about 160°C.
[0045] Referring now to Figure 2B, a method 150 of forming a molded article or component
of an article is also provided in which the article-forming (i.e., UV radiation curable)
material is introduced 155 in the mold described above that comprises a mold wall
formed at least partially of the cyclic olefin copolymer. The article-forming material
contacts 160 the molding surface of the surface of the mold wall in order to form
the molded article or component. When desirable, the cyclic olefin copolymer may comprise
a copolymer of polyethylene and norbornene.
[0046] When desirable, various precautions or safeguards may be undertaken by one skilled
in the art in order to protect 153 at least a portion of the UV- curable material
from being exposed to UV radiation during one or more steps of the method. Such precautions
or safeguards may include, but not be limited to, masking a portion of the UV radiation
curable material or the surface upon which the material is in contact, as well as
maintaining the UV radiation curable material in an environment that is absent any
UV light or visible light or both.
[0047] The mold wall is at least partially transparent; alternatively, substantially transparent
to UV light or radiation. In this sense, the method may further comprise transmitting
165 the UV light through the mold wall to the molding surface for exposing the article-forming
material to the UV light. The UV radiation curable material is cured 170 in response
to being exposed to the UV radiation. The UV radiation curable material is exposed
to the UV radiation in an amount and for a duration that is sufficient to partially
cure or fully cure the UV radiation curable material.
[0048] For the purpose of this disclosure, the term "partially cured" is intended to denote
the occurrence of at least about 1 %, alternatively, at least about 5% of the total
polymerization required to achieve a substantially full cure. The term "fully cured"
is intended to mean a substantially full cure in which the degree of curing is such
that the physical properties of the UV radiation curable material does not noticeably
change upon further exposure to additional UV radiation.
[0049] The UV radiation curable material generally comprises one or more photopolymers or
light-activated resins that will undergo a cross-linking reaction upon exposure to
UV radiation. The UV radiation curable material may comprise a mixture of various
multifunctional monomers, oligomers, and/or low molecular weight polymers or copolymers,
along with one or more photoinitiator(s) that can undergo polymerization in the presence
of UV radiation. Upon exposure to UV radiation, the photoinitiator decomposes into
a reactive species that activates polymerization of specific functional groups that
are present in the multifunctional oligomers, monomers, or polymers.
[0050] As used herein, the term "polymer" refers to a molecule having polymerized units
of one or more species of monomer. The term "polymer" is understood to include both
homopolymers and copolymers. The term "copolymer" refers to a polymer having polymerized
units of two or more species of monomers, and is understood to include terpolymers.
As used herein, reference to "a" polymer or other chemical compound refers one or
more molecules of the polymer or chemical compound, rather than being limited to a
single molecule of the polymer or chemical compound. Furthermore, the one or more
molecules may or may not be identical, so long as they fall under the category of
the chemical compound. Thus, for example, "a" polyurethane is interpreted to include
one or more polymer molecules of the polyurethane, where the polymer molecules may
or may not be identical (e.g., different molecular weights).
[0051] The end result of curing a light-activated resin in this manner is the formation
of a thermoset or cross-linked polymer network. Thus, the UV radiation curable material
may be described as being an UV radiation curable elastomer. Alternatively, the UV
radiation curable material may comprise an UV radiation curable rubber. The UV radiation
curable material may comprise one or more thermoset polymers, thermoplastic polymers,
or combinations thereof. When desirable, the one or more thermoplastic polymers may
be one or more thermoplastic polyurethanes (TPU).
[0052] Several specific examples of various monomers that may be used in the UV radiation
curable material include, but are not limited to, styrene and styrenic compounds,
vinyl compounds, vinyl ethers, N-vinyl carbazoles, lactones, lactams, cyclic ethers,
cyclic acetals, and cyclic siloxanes. Several specific examples of oligomers and low
molecular weight polymers or copolymers that may be incorporated into the UV radiation
curable material include, without limitation, vinyl butadiene, epoxides, urethanes,
polyethers, or polyesters, each of which provide specific properties to the resulting
material. Each of these oligomers or polymers may be functionalized using an acrylate.
Alternatively, the UV radiation curable material may include a mixture of urethane
and acrylate oligomers or a copolymer thereof.
[0053] Photoinitiation may occur via a free radical mechanism, an ionic mechanism, or a
combination thereof. Under an ionic mechanism, the polymerizable oligomers, monomers,
or polymers are doped with either anionic or cationic photoinitiators. Several examples
of such photoinitiators, include without limitation, onium salts, organometallic compounds,
and pyridinium salts. In the free radical mechanism, the photoinitiators generate
free-radicals by the abstraction of a hydrogen atom from a donor or co-initiator compound
(i.e., a 2-component system), or by the cleavage of a molecule (i.e., a 1-component
system). Several specific examples of abstraction type photoinitiators, include but
are not limited to, benzophenone, xanthones, and quinones with common donor compounds
being aliphatic amines. Several specific examples of cleavage-type photoinitiators
include, without limitation, benzoin ethers, acetophenones, benzoyl oximes, and acylphosphines.
Photocurable materials that form through the free-radical mechanism undergo chain-growth
polymerization, which includes three basic steps: initiation, chain propagation, and
chain termination. Alternatively, the photoinitiators are independently selected and
may include phosphine oxides, benzophenones, a-hydroxy-alkyl aryl ketones, thioxanthones,
anthraquinones, acetophenones, benzoins and benzoin ethers, ketals, imidazoles, phenylglyoxylic
acids, peroxides, and sulfur-containing compounds.
[0054] The amount of photoinitiators present in the UV radiation curable material is determined
by the effective amount necessary to induce crosslinking of the UV radiation curable
material. This amount may range from about 0.05 weight percent (wt. %) to about 5
wt. %, alternatively, from about 0.1 wt. % to about 2 wt. %, and alternatively, from
about 0.2 wt. % to about 1 wt. % based on the weight of the UV radiation curable material.
A single type of photoinitiator or a mixture of different photoinitiators may be used.
[0055] For the purpose of this disclosure, the term "weight" refers to a mass value, such
as having the units of grams, kilograms, and the like. Further, the recitations of
numerical ranges by endpoints include the endpoints and all numbers within that numerical
range. For example, a concentration ranging from 40% by weight to 60% by weight includes
concentrations of 40% by weight, 60% by weight, and all concentrations there between
(e.g., 40.1%, 41%, 45%, 50%, 52.5%, 55%, 59%, etc.).
[0056] According to another aspect of the present disclosure, the UV radiation curable material
may comprise, consist of, or consist essentially of a millable polyurethane gum that
includes ethylenic unsaturation, one or more photoinitiators, and at least one additional
crosslinking additive that comprises two or more ethylenically unsaturated groups.
The millable polyurethanes may be prepared by the reaction of a di- or polyisocyanate
with bis(hydroxyl)-functional compounds, at least one of which contains ethylenic
unsaturation. Alternatively, unsaturated polyester polyols may be used, alone or in
combination with other isocyanate-reactive components, such as polyoxyalkylene glycols
and/or diols capable of providing pendent ethylenic unsaturation. A commercial example
of such a UV radiation curable material is Millathane® UV (TSE Industries Inc., Clearwater,
FL). A further description of such UV radiation curable materials is provided in
U.S. Publication No. 2016/0362552, the entire content of which is hereby incorporated by reference.
[0057] For the purpose of this disclosure, the terms "at least one" and "one or more of'
an element are used interchangeably and may have the same meaning. These terms, which
refer to the inclusion of a single element or a plurality of the elements, may also
be represented by the suffix "(s)"at the end of the element. For example, "at least
one polyurethane", "one or more polyurethanes", and "polyurethane(s)" may be used
interchangeably and are intended to have the same meaning.
[0058] The additional crosslinking additive present in the curable polyurethane composition
may include any low molecular weight compounds that contain two or more ethylenically
unsaturated groups. These unsaturated groups may include, without limitation, glycerol
diallyl ether, 1,6-hexanediol di(meth)acrylate, triallylisocyanurate, trimethylolpropane
di(meth)acrylate, trimethylolpropane tri(meth)acrylate, glycerol di(meth)acrylate,
glycerol tri(meth)acrylate, propoxylated glycerol triacrylate, 1,2-divinyltetramethyldisiloxane,
divinylbenzene, and the like. The molecular weight of this additional crosslinking
additive may be less than about 2000 Da, alternatively less than about 1000 Da, alternatively
less than about 500 Da. The concentration of the crosslinking additive in the UV radiation
curable material is selected based upon the amount of ethylenic unsaturated groups
that are desired. The concentration of this additive may range from about 0.01 wt.
% to about 15 wt. %, alternatively, from about 1 wt. % to about 12 wt. %, and alternatively,
from about 5 wt. % to about 10 wt. % based on the overall weight of the UV radiation
curable material.
[0059] When desirable, the UV radiation curable material may optionally comprise one or
more additional processing aids, including without limitation, plasticizers, mold
release agents, lubricants, antioxidants, flame retardants, dyes, pigments, reinforcing
and non-reinforcing fillers, fiber reinforcements, and light stabilizers or UV absorbers.
When an UV absorber is incorporated into the UV radiation curable material in order
to enhance the environmental stability thereof, it may be necessary or desirable to
use a more powerful UV light source to achieve full cure of the material, or use an
UV light source having an output wavelength that is in a range within the UV spectrum
at which the UV absorber exhibits a reduced level of absorbance.
[0060] The reinforcing fillers that may optionally be incorporated into the UV radiation
curable material may be organic, i.e. polymeric, or inorganic in nature. These fillers
may exhibit a mean, weight average particle sizes that is ≤ 1 µm, alternatively, in
the range between about 20 nanometers (nm) to about 500 nm. Several specific examples
of reinforcing fillers include, but are not limited to, pyrogenic (i.e., fumed) metal
oxides, such as alumina, titania, ceria, silica, and the like; colloidal metal oxides,
such as colloidal alumina or silica; carbon black and acetylene black; metal hydroxides,
such as aluminum hydroxide; glass or polymer microspheres; or limestone, talc, clay,
and the like. The amount of filler present in the UV radiation curable material is
selected based upon the requirements associated with a particular end use. Typically,
the amount of reinforcing filler present in the UV radiation curable material ranges
from 0 wt. % to about 20 wt. % based on the total weight of the UV radiation curable
material. Fillers having the same chemical composition may be considered to be non-reinforcing
fillers when their mean, weight average particle size is greater than 1 µm, alternatively,
in the range of about 2 mm to about 500 mm.
[0061] The UV radiation curable material may be cured by irradiation with UV light transmitting
a wavelength that is the same as the excitation wavelength exhibited by the photoinitiator
present. The duration in time that the UV radiation curable material is irradiated
with UV radiation is variable and based upon the nature and type of reactive oligomers,
monomers, or polymers present in the UV radiation curable material, as well as type
and concentration of the crosslinking additives, photoinitiators, and fillers, as
well as the type and power associated with the available UV light source. The duration
of UV exposure may range less than a second to several hours; alternatively, the exposure
time is between about 1 second and about 1 hour; alternatively, between about 5 seconds
and 5 minutes. The UV radiation curable material may be irradiated at ambient or room
temperature within the confines of a molding operation or at a temperature associated
with the component formed in a molding or extrusion process. When desirable the molded
part may be subjected to a cooling step prior to irradiation with UV light. Although,
no thermal cure is necessary, a dual cure system may be used when desirable.
[0062] According to another aspect of the present disclosure, the article or component of
the article formed from the UV radiation curable material according to the teachings
of the present disclosure may be, without limitation, a garment, sporting equipment,
or footwear. Alternatively, the article is component of a garment, sporting equipment,
or footwear. For example, referring to Figures 3A and 3B, the component of sporting
equipment may be a part or section 175 of a backpack 180 or a hat 190 , including
but not limited to a logo. Similarly, as shown in Figure 3C, the component of a garment
may be a part or section 175 of a shirt 195. In Figures 4A and 4B, the component of
the article of footwear 200 may be an outsole 220, for example, or a logo or other
component 240. As used herein, the terms "article of footwear" and "footwear" are
intended to be used interchangeably to refer to the same article. Typically, the term
"article of footwear" will be used in a first instance, and the term "footwear" may
be subsequently used to refer to the same article for ease of readability.
[0063] The article of footwear or shoe of the present disclosure may be designed for a variety
of uses, such as sporting, athletic, military, work-related, recreational, or casual
use. The article of footwear may be used outdoors on paved or unpaved surfaces (in
part or in whole), such as on a ground surface including one or more of grass, turf,
gravel, sand, dirt, clay, mud, and the like, intended for the performance of an athletic
competition or as a general outdoor surface. The article of footwear may also be desirably
used with indoor activities, such as indoor sports, shopping, and everyday work.
[0064] Referring now to Figures 4A and 4B, the footwear 200 or shoe 200 may comprise, consist
of, or consist essentially of an upper 210 and an outsole 220 having a predetermined
shape. The outsole 220 is in contact with and attached to the upper 210. At least
part of the upper 210 and/or the outsole 220 comprises the UV radiation curable material
as described above and further defined herein in an uncured or partially cured state.
[0065] Still referring to Figures 4A and 4B, the outsole 220 refers to the very bottom of
the shoe that is in direct contact with the ground. The outsole 220 may be relatively
smooth or include one or more traction elements 225. These traction elements 225 may
provide enhanced traction, as well as provide support or flexibility to the outsole
and/or provide an aesthetic design or look to the shoe. The traction elements 225
may include, but are not limited to a tread pattern, as well cleats, studs, spikes,
or similar elements configured to enhance traction for a wearer during cutting, turning,
stopping, accelerating, and backward movement.
[0066] Since the outsole 220 is the outer most sole of the shoe, it is directly exposed
to abrasion and wear. Similarly, portions of the upper 210 are directly exposed to
abrasion and wear. Various portions of the outsole 220 may be constructed with different
thickness and exhibit different degrees of flexibility. The materials that comprise
the outsole 220 should provide some degree of waterproofing, durability, and possess
a coefficient of friction that is high enough to prevent slipping. In some cases two
or more materials of different densities can be incorporated into the outsole 220
to give a hard wearing outer surface and a softer, more flexible midsole 230 for greater
comfort. The upper 210 and/or the outsole 220 may be a single layer or may contain
multiple layers of the same or similar material, provided at least a portion of the
upper 210, at least a portion of the outsole 220, or portions of both the upper 210
and the outsole 220 comprise an UV radiation curable material. Alternatively, substantially
all of the outsole comprises an UV radiation curable material.
[0067] The outsole 220 may be directly or otherwise operably secured to the upper 210 using
any suitable mechanism or method. As used herein, the terms "operably secured to",
such as for an outsole that is operably secured to an upper, refers collectively to
direct connections, indirect connections, integral formations, and combinations thereof.
For instance, for an outsole that is operably secured to an upper, the outsole can
be directly connected to the upper (e.g., adhered directly thereto or glued with a
cement or an adhesive), can be integrally formed with the upper (e.g., as a unitary
component), and combinations thereof.
[0068] Still referring to Figures 4A and 4B, the upper 210 of the footwear 200 has a body
which may be fabricated from materials known in the art for making articles of footwear,
and is configured to receive a user's foot. The upper 210 of a shoe consists of all
components of the shoe above the outsole 220. The different components of the upper
210 may include a toe box, heal counter, and an Achilles notch, to name a few. These
components are attached by stitches or adhesives to become a single unit to which
the outsole is attached.
[0069] The upper 210 or components of the upper 210 may comprise a soft body made up of
one or more lightweight materials. When desirable, the UV radiation curable material
may be used to form a portion of the upper and/or a portion of a component of the
upper. Such components of the upper may include, but not be limited to, a toe cap,
a heel counter, a rand, or an eyelet stay, to name a few.
[0070] The materials used in the upper 210 provide stability, comfort, and a secure fit.
For example, the upper may be made from or include one or more components made from
one or more of natural or synthetic leather, a textile or both. The textile may include;
a knit, braided, woven, or nonwoven textile made in whole or in part of a natural
fiber; a knit, braided, woven or non-woven textile made in whole or in part of a synthetic
polymer, a film of a synthetic polymer, etc.; and combinations thereof. The textile
may include one or more natural or synthetic fibers or yarns. The synthetic yarns
may comprise, consist of, or consist essentially of thermoplastic polyurethane (TPU),
polyamide (e.g., Nylon®, etc.), polyester (e.g., polyethylene terephthalate or PET),
polyolefin, or a mixture thereof.
[0071] The upper 210 and components of the upper 110 may be manufactured according to conventional
techniques (e.g., molding, extrusion, thermoforming, stitching, knitting, etc.). While
illustrated in Figures 4A and 4B as a generic design, the upper 310 may alternatively
have any desired aesthetic design, functional design, brand designators, or the like.
[0072] Still referring to Figures 4A and 4B, the upper 210 may further comprise laces, flaps,
straps, or other securing or foot engagement structures 213 used to securely hold
the shoe 200 to a wearer's foot. A tongue member, bootie, or other similar type structure
may be provided in or near the shoe instep area in order to increase comfort and/or
to moderate the pressure or feel applied to the wearer's foot by any foot engagement
structures 213.
[0073] When desirable, at least a portion of the upper 210 of the article of footwear, and
in some embodiments substantially the entirety of the upper, may be formed of a knitted
component. According to one aspect of the present disclosure, one or more pieces may
be cut from a warp knit textile or a weft knit textile and assembled to form a portion
of the upper 210. According to another aspect of the present disclosure, the upper
may be formed by knitting to shape one or more large portions using, for example,
flat knitting or circular knitting techniques. The upper may be formed by stitching
together areas of the flat or circular knit, such as stitching together edges of a
flat knit component, or stitching together the toe region of a circular knit component.
The knitted component may additionally or alternatively form another element of the
article of footwear 210 such as the insole, for example.
[0074] The knitted component may have a first side forming an inner surface of the upper
210 (e.g., facing the void of the article of footwear 200) and a second side forming
an outer surface of the upper 210. An upper 210 including the knitted component may
substantially surround the void so as to substantially encompass the foot of a person
when the article of footwear is in use. The first side and the second side of the
knitted component may exhibit different characteristics (e.g., the first side may
provide abrasion resistance and comfort while the second side may be relatively rigid
and provide water resistance). The knitted component may be formed as an integral
one-piece element during a knitting process, such as a weft knitting process (e.g.,
with a flat knitting machine or circular knitting machine), a warp knitting process,
or any other suitable knitting process. That is, the knitting process may substantially
form the knit structure of the knitted component without the need for significant
post-knitting processes or steps. Alternatively, two or more portions of the knitted
component may be formed separately and then attached. In some embodiments, the knitted
component may be shaped after the knitting process to form and retain the desired
shape of the upper (for example, by steaming the knitted component or fusing portions
of the knitted component while the knitted component is on a foot-shaped last). The
shaping process may include attaching the knitted component to another component (e.g.,
a strobel, etc.) and/or attaching one portion of the knitted component to another
portion of the knitted component at a seam by sewing, by using an adhesive including
a heat-activated adhesive, or by another suitable attachment process.
[0075] Forming the upper 210 with the knitted component may provide the upper 210 with advantageous
characteristics including, but not limited to, a particular degree of elasticity (for
example, as expressed in terms of Young's modulus), breathability, bendability, strength,
moisture absorption, weight, and abrasion resistance. These characteristics may be
accomplished by selecting a particular single layer or multi-layer knit structure
(e.g., a ribbed knit structure, a single jersey knit structure, or a double jersey
knit structure), by varying the size and tension of the knit structure, by using one
or more yarns or monofilaments formed of a particular material (e.g., a polyester
material or an elastic material, such as spandex), by selecting yarns of a particular
size (e.g., denier), or a combination thereof. The knitted component may also provide
desirable aesthetic characteristics by incorporating yarns having different colors
or other visual properties arranged in a particular pattern. The yarns and/or the
knit structure of the knitted component may be varied at different locations such
that the knitted component has two or more portions with different characteristics
(e.g., a portion forming the throat area of the upper may be relatively elastic while
another portion may be relatively inelastic). Yarns may also be coated with different
materials, such as thermoplastic materials that have a lower melting point than the
thermoplastic material that forms the core of the yarn.
[0076] In some embodiments, the knitted component may incorporate one or more materials
with properties that change in response to a stimulus (e.g., temperature, moisture,
electrical current, magnetic field, or light). For example, the knitted component
may include yarns formed of a thermoplastic polymer material (e.g., polyurethanes,
polyamides, polyolefins, and nylons) that transitions from a solid state to a softened
or liquid state when subjected to certain temperatures at or above its melting point
and then transitions back to the solid state when cooled. The thermoplastic polymer
material may provide the ability to heat and then cool a portion of the knitted component
thereby forming an area of bonded or continuous material that exhibits certain advantageous
properties including a relatively high degree of rigidity, strength, and water resistance,
for example.
[0077] In some embodiments, the knitted component may include one or more yarns or strands
that are at least partially inlaid or otherwise inserted within the knit structure
of the knitted component during or after the knitting process, herein referred to
as "tensile strands." The tensile strands may be substantially inelastic so as to
have a substantially fixed length. The tensile strands may extend through a plurality
of courses of the knitted component or through a passage within the knitted component
and may limit the stretch of the knitted component in at least one direction. For
example, the tensile strands may extend approximately from a bite-line of the upper
to a throat area of the upper to limit the stretch of the upper in the lateral direction.
The tensile strands may form one or more lace apertures for receiving a lace and/or
may extend around at least a portion of a lace aperture formed in the knit structure
of the knitted component.
[0078] When desirable, the article of footwear 200 or shoe 200 may also include a platform
upon which the foot will rest that separates the upper 210 from the foot of the person
wearing the shoe. This platform is typically a separate removable layer called an
insole or sock liner (not shown) that is made of cellulose or other materials, such
as thermoplastic or thermoset elastomers, including foam materials, capable of providing
a cushion between the ground and the foot of the person wearing the shoe 200. The
insole may be treated with additives to inhibit bacterial growth. When desirable,
the insole may be incorporated with, e.g., sewn into, the upper.
[0079] Referring once again to Figures 4A and 4B, the outsole 220 of the shoe 200 may be
engaged with or attached to the upper 210 and be directly adhered thereto. However,
when desirable, a portion of the outsole may be attached to the upper 210 through
the use of additional means conventionally known or used in the construction of footwear
200, such as through the use of cements or adhesives, by mechanical connectors, and
by sewing or stitching, to name a few.
[0080] When desirable, the UV radiation curable material may be used to attach two or more
elements together. More specifically, the UV radiation curable material may be applied
to a textile or another portion of an upper and used to secure another or second layer
of a material thereto. This second or additional layer may also be a textile, or it
can be an injection molded component or even a decorative element. The second layer
may be made of a material whose composition is similar to or different than the textile
to which it is being attached.
[0081] The UV radiation curable material may also be used to overcoat a second layer that
has been secured to the upper. When placed on top of the second layer, the UV radiation
curable material may provide abrasion-resistance and/or act as a protective layer.
[0082] According to another aspect of the present disclosure, a method 400 of forming an
article of footwear is provided as shown in Figure 5. This method comprises the steps
of providing 405 a molded article in the form of a molded footwear component and affixing
410 the molded component with an upper and optionally with other footwear components
to form the article of footwear. As used for the purpose of this disclosure, the term
"providing" may be defined as receiving, supplying, or making available something
wanted or needed
[0083] The following specific examples are given to illustrate the formation of an article
or a component of an article according to the teachings of the present disclosure
and should not be construed to limit the scope of the disclosure. One skilled in the
art will further understand that any properties reported herein represent properties
that are routinely measured and can be obtained by multiple different methods. The
methods described herein represent one such method and other methods may be utilized
without exceeding the scope of the present disclosure.
EXAMPLE 1
[0084] This Example demonstrates the formation of an article using a mold having a molding
surface that is transparent to UV radiation according to the teachings of the present
disclosure. Referring now to Figure 6, a mold 1 was designed to fit within a 7.5"
width benchtop conveyor line of an UV curing apparatus 25. The UV curing apparatus
25 was a LC6B/LC6B-2 curing unit (Heraeus Noblelight America LLC, Gaithersburg, MD).
The UV lamp 20 used in this apparatus 25 to cure the article-forming (i.e., UV radiation
curable) material was a metal halide bulb. The mold 1 was selected to have the most
basic geometry, i.e., a 4" X 4" herringbone mold 1 with a cavity 5 capable of being
completely filled with the article-forming material. The mold 1 was comprised of a
bulk material 10 and a mold wall 15 that was formed of a cyclic olefin copolymer.
The mold 1 was designed for use in a compression molding process.
[0085] A cured article 30 was formed using a paired mold 1. The mold 1 was a one-sided female
mold having a mold wall 15 with a herringbone structure. The other or opposite side
was pressed against a release paper. One skilled in the art will understand that other
surfaces, such as a metal shim (aluminum and stainless), acrylic (PMMA) plaque, or
some other flat plaque may be used as part of the mold 1 instead of release paper
without exceeding the scope of the present disclosure. The cyclic olefin copolymer
used to form the mold wall was TOPAS® Grade 6017 (Topas Advanced Polymers Inc., Florence,
KY, USA). The mold wall 15 was formed by placing the cyclic olefin copolymer into
a master molded and heated until cured. The cyclic olefin copolymer was processed
according to the manufacturer's technical specification.
[0086] The article-forming (i.e., UV radiation curable) material was supplied as a pre-compounded
sheet. The article-forming material was an UV radiation curable polyurethane rubber
(Millathane® DUV 8263, TSE Industries Inc., Clearwater, FL). The UV radiation curable
material was processed according to the manufacturer's technical specification. The
material was milled to a thinner thickness, which reduced air voids. The article-forming
material was placed in to the mold and compressed using a traditional compression
press (two-platen system) with the application of pressure above 60 psi. The temperature
of the mold was adjusted depending upon the application. In this example, the temperature
of the mold was maintained at a temperature up to about 160°C.
[0087] Referring again to Figure 6, after the article-forming material was compressed in
the mold 1, the combination of the mold and article-forming material was placed through
a UV curing station as described above. The resulting molded article 30 was then removed
from the mold 1.
EXAMPLE 2
[0088] This example demonstrates the formation of a component of an article using a mold
having a molding surface that is transparent to UV radiation according to the teachings
of the present disclosure. Referring now to Figure 7A, a UV radiation curable material
33 is placed in contact with a fabric 35. In this example, the UV radiation curable
material 33 is an UV radiation curable polyurethane rubber (Millathane® UV, TSE Industries
Inc., Clearwater, FL) processed according to the manufacturer's technical specification.
The material may be applied as two layers 31, 33 if desirable in order to provide
a variable thickness, or the second layer 31 may be of a different material. The UV
radiation curable material was pre-dried to remove surface moisture prior to use.
[0089] Referring now to Figure 7B, the UV radiation curable material 33 and textile 35 are
placed into the mold 1. The mold 1 in this example is the same mold 1 described above
in Example 1. This mold comprises an outer bulk material 5 and a mold wall 15 having
a herringbone design. In this mold at least the mold wall 15 comprises a cyclic olefin
copolymer that exhibits transparency to UV radiation.
[0090] In Figure 7C, the mold 1 with the UV radiation curable material 33 and fabric 35
are compressed using a traditional T-shirt press with the application of pressure
in the range of about 20 psi to about 60 psi. In this example, the temperature of
the mold was kept below 135°C in order to minimize the potential for dye migration
from the fabric 35.
[0091] Referring now to Figure 7D, the compressed mold 1 was placed on a conveyer that moved
the mold 1 into alignment with a UV light source 20 as part of the UV curing apparatus
25. The resulting molded article 30 was then removed from the mold 1. Finally, as
shown in Figure 7E, the finished article with the molded component formed therein
30 was removed from the mold. As shown in Figure 7E, the finished component of the
article adheres to the fabric and incorporates the herringbone pattern of the mold.
[0092] Within this specification, embodiments have been described in a way that enables
a clear and concise specification to be written, but it is intended and will be appreciated
that embodiments may be variously combined or separated.